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MATERIALS IN DESIGN & PROTOTYPING PRODUCTS carbon fibre reinforced composites approved for use in space


Carbon fibre reinforced composite Windform RS and Glass fibre reinforced composite Windform LX 3.0, from CRP Technology's Windform TOP-LINE, have passed ESA standard screening outgassing tests in accordance with ESA-TEC-PR-002015 (based on ECSS-Q-ST-70-02C). This means they are officially approved for the construction of applications to launch into space. Franco Cevolini, CEO and technical director


of CRP Technology, commented: “Passing the outgassing tests is a crucial factor for those who supply materials to the space industry. The


majority of Windform TOP-LINE composites are already approved for space applications, and now that two more Windform composites are officially compliant with ESA outgassing requirements we are more competitive and ready to offer further added value to our most demanding customers.”


cRp technology crptechnology.com


windform.com


COMPANY DEvELOPS RECYCLED NYLON 66 RECOvERED fROM SILICONE-COATED AIRbAGS


Toray Industries has developed recycled nylon 66 recovered from silicone-coated airbag fabric scrap cuttings. This material is said to achieve the same flowability and mechanical properties as injection moulding grades from virgin nylon 66. The product – Ecouse AMILAN – was


created by combining additives with resin that REFINVERSE Group recycled by stripping silicone from airbag fabric scrap cuttings, and then washed. The nylon 66 fabric used in airbags can be silicone-coated or non-coated. Recycling coated


airbag fabric scrap cuttings requires removing the silicone, however recycling through stripping and washing has typically left silicone traces. So, Toray combined particular additives so


residual silicone resin would not migrate to the surface of moulded products, and reduced mould adhesion. That is why the flowability and mechanical properties of recycled nylon 66 are on par with those of virgin nylon 66.


toray www.toray.com


hIGh qUALITY LIGhTwEIGhT SUSTAINAbLE SANDwICh PANELS DEvELOPED


ThermHex Waben, specialist producer of thermoplastic polypropylene honeycomb cores for lightweight sandwich panels and components, has developed a range of sustainable panels for applications in industries including automotive, transport, wind and solar, logistics, B&C, and furniture. The thermoplastic composite panels are said to have excellent mechanical performance and a surface quality not achievable with


conventional honeycomb technology with thermoplastic composite skins. Measuring in thickness from 6mm up to 20mm and with densities from


1200g/m² to 4200g/m², the honeycomb panels are produced very economically under the EconCore patented production process. They are increasingly replacing more traditional materials, such as plywood and thermoset panels, particularly in trucks, trailers and cargo boxes. They are produced in a continuous in-line process by the extrusion of a


polypropylene film, vacuum forming and folding. Allowing for direct and automated lamination of thermoplastic composite skins, this integrated process very effectively generates a honeycomb sandwich panel of outstanding performance. Due to the smaller 5mm cell size of the honeycomb, ThermHex Waben’s


cores deliver exceptional surface quality even with very thin skin layers. The company has almost halved the cell size which has enabled new and existing industries to develop new applications, not just due to its high strength to weight ratio but also now the surface finish. One of these applications is the visible surface of parts for cars and


trucks. ThermHex Waben’s polypropylene honeycombs are being used in a range of automotive interior parts. Due to the lightweight nature of the material, the manufacturers were able to reduce the weight of the vehicles without compromising on rigidity which saved on fuel efficiency. In addition, sustainability is an important consideration within all these


industries and Thermhex Waben’s polypropylene is helping manufacturers to achieve this.


thermhex https://thermhex.com/


MARCh 2023 Design solUtions 45


cReating a lightweight bike foR the olympics


In 2019, British Cycling invited Renishaw to join the Tokyo Olympic’s bike development team, where its expertise in metal 3D printing and advanced engineering was seen as vital to enable the production of lighter, more complex components, than traditional manufacturing methods. This enabled the team to increase the bike’s speed. For the Tokyo bike, Renishaw used its in-house


expertise to rapidly produce plastic and metal prototype parts to undertake aerodynamic testing of the new design and ensure that parts were light, geometrically correct and strong enough to endure the strain from riders. Once it confirmed the parts were viable, the company then used its RenAM 500Q AM systems to manufacture aluminium and titanium parts, including handlebars, for the competition bikes, with parts customised for individual athletes. Going forward, Renishaw will use its expertise in


additive manufacturing (AM) to create lightweight, complex parts for an upgraded track bike design, which aims to reduce drag and improve overall speeds for the 2024 Paris Olympics. The goal is to increase the bike’s speed through an enhanced design that will further improve the team’s performance.


Renishaw www.renishaw.com/am


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